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Home › Saturn › 2005 › Ion Red Line › Repair and Diagnosis › Engine Mechanical › Engine Exhaust System › Repair Instructions › Exhaust Manifold Replacement (LSJ) › Installation Procedure

Installation Procedure

  1. Install a new exhaust manifold gasket.
  2. Install the exhaust manifold to the cylinder head.
    3. Fig 1: View Of Exhaust Manifold
    GM1398727Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: Install the new exhaust nuts.
  3. Install the new exhaust manifold to cylinder head retaining nuts. Follow the tightening sequence.

    Tighten:  Tighten the nuts to 13 N.m (115 lb in).

    4. Fig 2: Exhaust Manifold Bolt Tightening Sequence
    GM1340643Courtesy of GENERAL MOTORS CORP.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Install a new exhaust manifold to flex coupler gasket.
  6. Push the flex coupler into position on the exhaust manifold.
    7. IMPORTANT: Install the new exhaust nuts.
  7. Install the retaining nuts which secure the manifold to the flex decoupler.

    Tighten:  Tighten the nuts to 50 N.m (37 lb ft).

    8. Fig 3: View Of Exhaust Takedown Pipe
    GM878834Courtesy of GENERAL MOTORS CORP.
  8. Lower the vehicle.
  9. Install the oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Position 1 in Engine Controls - 2.0L (LSJ).
    10. Fig 4: Oxygen Sensor & Harness Connector
    GM412121Courtesy of GENERAL MOTORS CORP.
  10. Install the exhaust manifold heat shield.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    11. Fig 5: Removing & Installing Exhaust Manifold Heat Shield
    GM746055Courtesy of GENERAL MOTORS CORP.
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